Drill Bank Setup & Operation

Drill Bank Example Drawing

The numbers 20-29 are straight drills and the numbers 14-19 are horizontal drills. 

Drill Bank 1 Setup

Map all overall drill bank features according to the requirements for the drill bank to begin and end a cycle

NOTE: Every drill bank is unique on how it functions. basic understanding of the sequence is required for setup in the parameter blocks below! Not all parameters have functions that correlate to every drill bank. Some may be left blank.

1: "Engaged Input" is a confirmation signal to determine that the drill bank assembly did reach its desired engaged position. This is typically a magnetic switch on the air solenoid controlled by the "Engaged Output". This creates a more robust product if available but not mandatory for operation.

2: "Engaged Output" is the first action to occur when a drill cycle is called. This is typically an air cylinder to extend the drill bank assembly into a cutting position.

3: "Engaged Settle Time" may be required if no "Engaged Input" is present. This will allow the drill bank assembly time to reach its proper position before beginning operation. This logic is true for all "Settle Time" style parameters

4: "Drill Bank Motor On Output" is where you would map the output for the contactor for the drill motor that actually spins the drills.

5: "Parked Input" is the same logic but opposite direction of the "Engaged Input". "Engaged"=Prepared for cycle to start. "Parked"=Prepared for cycle to end.

6: "Parked Output" is the same logic but opposite direction of the "Engaged Output" Engaged=Move drill bank assembly to cut position. "Parked=Move drill bank assembly out of the way to resume standard operation. "Engaged" and "Parked" are typically opposing directions of the same cylinder.

7: "Drill Bank 1 Range of Tool Numbers for Drill Bank" will have a range of numbers from the lowest drill tool number to the highest. (Ex. If i have 16 drills in my bank assembly, I may input "100-111" into the "Drill Bank 1 Range of Tool Numbers for Drill Bank" Parameter *And the remaining amount, "112-115", would go into "Drill Bank 2 Range of Tool Numbers for Drill Bank"*). Tool numbers for drills should be in a range that will not overlap or interfere with standard Spindle tooling numbers. Starting at 100 for drill bank tool numbers is usually a safe bet for clarity and separation from standard spindle tooling, however, you have full control as to which numbers you choose as long you input proper data into this "Drill Bank 1 Range of Tool Numbers for Drill Bank" Parameter.

8: "Drill Bank Number of Drill Banks Enabled" needs to be set to 1 or 2 as required.

Map individual drill solenoid outputs as needed.

"Drill Bank # All Drills Up Output" is where you would map the output signal for any existing solenoid that would retract all drill tools.

"Drill Bank # Drill # Down Output" is where you would map the output signal for whichever given tool you want to fire to extend to a cut height. Tool #100 is the FIRST tool in the sequence so its solenoids output would be mapped to "Drill Bank 1 Drill 1 Down Output". Tool #101s output would be mapped to "Drill Bank 1 Drill 2 Down Output" and so on in order. Select the proper output signal to fire the solenoid associated to whichever tool number you are wanting to extend. (Ex. Lets say that I still have the same numbers in my "Drill Bank 1 Range of Tool Numbers for Drill Bank" Parameter as the example above "100-111" for my 16 tool drill bank. If I am wanting tool #100 to extend when I call M6 T100, I would map the output signal that extends tool #100 to "Drill Bank 1 Drill 1 Down Output". If I wanted to fire tool #111, I would map the output signal that extends tool #111 to the "Drill Bank 1 Drill 12 Down Output". Every tool, 100-111, will be in order from "Drill Bank 1 Drill 1 Down Output" to "Drill Bank 1 Drill 12 Down Output".) Now as you can see from my example, I have more drill tools than I have available output parameters to map to in "Drill Bank 1". For this instance, I will have to map the remaining tools in the "Drill Bank 2" section. "Drill Bank 2 Drill 1 Down Output" will behave as an output for tool #112 and so on. * See "Drill Bank 2 Setup" below for specific instruction! *

"Drill Bank # Drill # Up Outputs" operate as the opposite of the "Drill Bank # Drill # Down Outputs". The "Up" outputs will raise the drill bank tools when the cycle is finished.

Most Drill Banks do not have "Drill Bank # Drill # Up Outputs" or "Drill Bank # All Drills Up Outputs"

Drill Bank 2 Setup

1-6: will be the same logic as Drill Bank 1 setup listed above. However, if you are only have 1 Drill Bank assembly and are using Drill Bank 2 as an extension to Drill Bank 1 because you have too many tools to fit in the output parameters of Drill Bank 1, then 1-6 for Drill Bank 2 will be identical to Drill Bank 1.

7: "Drill Bank 2 Range of Tool Numbers for Drill Bank" will be a continuation of the "Drill Bank 1 Range of Tool Numbers for Drill Bank" values if you do not actually have a second Drill Bank. (Ex. If "Drill Bank 1 Range of Tool Numbers for Drill Bank" has the value "100-111" but I can only use up to tool #111 in Drill Bank 1s parameter list, then my "Drill Bank 2 Range of Tool Numbers for Drill Bank" value should be "112-115".

If you actually do have a second Drill Bank, you cannot "trick" it like this and must use the same logic as Drill Bank 1 Setup.

Update the tool numbers in "C:\Mach4\Profiles\Router\ToolTables\ToolInfo.Lua"

The value in the "Spindle (1)" being "99" shows why its commonly good practice to start Drill Bank tool numbers with "100".

"Drill Bank (1)" "Start" and "Stop" need to reflect the value in 7: "Drill Bank 1 Range of Tool Numbers for Drill Bank".

"Drill Bank (2)" "Start" and "Stop" need to reflect the value in 7: "Drill Bank 2 Range of Tool Numbers for Drill Bank".

Default:

What it should be for this example:

"Tool Offsets" page is where all tool specific data will be input. Below is the Default Tool Offset table:

The Default Tool Offset table is limited to the data shown and only 99 tools total.

Select the "Optional Fields" checkmark in the Tool Offset table

Checking "Optional Fields" provides many more fields of data but the Tool Offsets table is still limited to 99 tools.

Go to Configure>Control>Tools

Change the "Max Tools" value to whatever your highest tool number will be including the Drill Bank.

Vertical Drill Parameters

NOTE: The data below will be for VERTICAL drills only! HORIZONTAL drills will be described below this section.

1: "Length" will have the same meaning as standard tooling and can even be done on a tool setter if possible. You must determine how far down the Drill Bank assembly must travel before the tip of that drill bit reaches the same "Zero" as your Spindle tool bit.

2: "Length Wear" has the same meaning as standard tooling.

3: "Diameter" is mostly non-functional but more for documentation. Unless a customer is using Cutter Comp on Drill Cycles, which I don't believe to be something that we have encountered yet, the 3:"Diameter" section can be blank with no issue. The true "Diameter" will be accounted for in the "X Offsets" and "Y Offsets" as needed.

4: "Diameter Wear" has the same meaning as standard tooling and is useless for Drill Bank tooling if 3:"Diameter" is also useless.

5: "Description" has no function and is strictly for note-keeping purposes.

6: "Pocket" should ALWAYS be 0 for Drill Bank tooling as to not conflict with standard Spindle tooling.

7: "X Offset" or "Offest" if spelled by a homeschooler, will be the distance from the center of your Spindle tool bit to the center of the Drill Bank tool bit you are setting up along the X Axis. This can be gathered by Zeroing the X and Y Axes, drilling a hole into material with the Spindle tool bit, and then jogging over until you are lined up with the hole with the Drill Bank tool you are trying to set up. Both X and Y Offsets can be achieved with the same hole alignment move. Input whatever distance is in your DRO into the 7: "X Offset" field. Add or Subtract from this value as needed to dial in the perfect alignment with the Spindle hole.

8: "X Offset Wear" has the same meaning as standard tooling. Not necessary for Drill Bank tooling.

9: "Y Offset" or "Offest" if spelled by a homeschooler, will be the distance from the center of your Spindle tool bit to the center of the Drill Bank tool bit you are setting up along the Y Axis. This can be gathered by Zeroing the X and Y Axes, drilling a hole into material with the Spindle tool bit, and then jogging over until you are lined up with the hole with the Drill Bank tool you are trying to set up. Both X and Y Offsets can be achieved with the same hole alignment move. Input whatever distance is in your DRO into the 9: "Y Offset" field. Add or Subtract from this value as needed to dial in the perfect alignment with the Spindle hole.

10: "Y Offset Wear" has the same meaning as standard tooling. Not necessary for Drill Bank tooling.

Often Fanuc will use separate fixture offsets for the Drill Bank positioning. (Ex. G54, G55)

32mm is a very common spacing distance between drills! You can often Add or Subtract 32mm in the appropriate direction to the remaining Drill bits "X Offsets" and "Y Offsets" after getting just one Drill bits position! 

Horizontal Drill Parameters

1: "Length" is NOT the same for horizontal drills as for vertical drills! 1: "Length" is still the VERTICAL distance to the top of the material. NOT the actual length of the horizontal drill bit! 1: "Length" for horizontal bits can be gathered touching off on top of a material with the Spindle tool bit, Zeroing the Z at that position, performing a tool change to whichever horizontal drill you desire, then touching off the horizontal drill to the top of the material, and inputting whatever the DRO shows for the Z Minus HALF of the horizontal drill bits Diameter! Input this value into the 1: "Length" field.

2: "Length Wear" has the same meaning as standard tooling.

3: "Diameter" is mostly non-functional but more for documentation. Unless a customer is using Cutter Comp on Drill Cycles, which I don't believe to be something that we have encountered yet, the 3: "Diameter" section can be blank with no issue. 

4: "Diameter Wear" has the same meaning as standard tooling and is useless for Drill Bank tooling if 3: "Diameter" is also useless.

5: "Description" has no function and is strictly for note-keeping purposes.

6: "Pocket" should ALWAYS be 0 for Drill Bank tooling as to not conflict with standard Spindle tooling.

7: "X Offset" or "Offest" if spelled by a homeschooler, will be the distance from the center of your Spindle tool bit to the tip of the Drill Bank tool bit you are setting up along the X Axis. A Horizontal drill bit that is pointed in line with the X Axis will have a "X Offset" as what would really be the "Tool Length" on a vertical tool. This value can be gathered by  jogging alongside a 3D material with the Spindle tool bit along the X Axis, Zeroing the X Axis, commanding a tool change to whichever horizontal tool you are trying to set up, and then jogging over until you are touching the side of the 3D material with the tip of the Drill Bank tool you are trying to set up. Add or Subtract half of the Diameter of the Spindle tool bit. Input whatever distance is in your DRO into the 7: "X Offset" field. Add or Subtract from this value as needed to dial in the perfect alignment with the 3D material.

8: "X Offset Wear" has the same meaning as standard tooling. Not necessary for Drill Bank tooling.

9: "Y Offset" or "Offest" if spelled by a homeschooler, will be the distance from the center of your Spindle tool bit to the tip of the Drill Bank tool bit you are setting up along the Y Axis. A Horizontal drill bit that is pointed in line with the Y Axis will have a "Y Offset" as what would really be the "Tool Length" on a vertical tool. This value can be gathered by  jogging alongside a 3D material with the Spindle tool bit along the Y Axis, Zeroing the Y Axis, commanding a tool change to whichever horizontal tool you are trying to set up, and then jogging over until you are touching the side of the 3D material with the tip of the Drill Bank tool you are trying to set up. Add or Subtract half of the Diameter of the Spindle tool bit. Input whatever distance is in your DRO into the 9: "Y Offset" field. Add or Subtract from this value as needed to dial in the perfect alignment with the 3D material.

10: "Y Offset Wear" has the same meaning as standard tooling. Not necessary for Drill Bank tooling.

If The Old Control Was A Fanuc Beware Binary Drill Calls!

If you see a single drill call where there should be several (ex "M91 T120")  but the program is expecting multiple drills to be dropped then the old control is probably using binary drill calls, this is where each drill has a unique number that is double the previous drill and the total of all of them is used as the tool number.   this can be deciphered with a good GC adapter.

When deciphering binary calls first try calling the drills from largest to smallest T numbers as this seems to be how Fanuc did it.

this is important because Mach will apply the XY offset in your tool table from the last drill called 

You will probably need to add an M6 T0 or a subprogram to retract all drills right before each new drill related M6 otherwise they will never get pulled back up.

The Fanuc manual explaining this is attached as a PDF

Onsrud Panel Pro 9 position Drill Bank

This may not  apply to all Onsruds or even all Panel Pros but the a Panel Pro that I did had X and Y offsets in the Post Processor that applied the offsets for every drill from the corner drill. This meant that X and Y offsets in the control were the same for all drill tools and it was the distance on X and Y from the spindle center to the corner drill center. Rumor has it that this is a common occurrence with Onsrud drill banks. This drill bank only had 9 tools and none of them were horizontal. I don't know how horizontal tools are handled by Onsrud.